Jurnal 1

Status	Date	Tags
Done or Ongoing	Tuesday, 24 September 2024	#Semester-5/Prosmanlog

Advances in Metal Casting Technology
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Introduction (Sejarah)

several thousand years ago: Copper based alloys (two part stone or ceramic mold)
6000 years ago: wax casting (indus valley civilization)
Industrial Revolution: iron and steel produced in large amount.
Light alloys aluminum, magnesium, and titanium alternative to bronze, brass, iron and steel
19th century: automobiles (new products and high productivity processes)
- Casting industry (mid 19th century): high and low pressure die casting
- 1849: patent for an initial manually operated device grantes to sturges.
- 1855: further automation in casting process is needed -> need small parts and high volume production
20th century: aluminum pressure die casting
- linked with automotive industry
- cold chamber hpdc system established before second world war
Thir Industrial Revolution: computer numerical control, the implementation of automated system as a replacement to human control.
Fourth industrial revolution: AI (using large amount of data)

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Intinya: technological development in metal casting is considering current trends in market and boundary condition.

Global Casting Industry: Facts and Figures (Current Time)

2000s to 2018: constant rise in output interupted from stagnant 2007-2010 and 2014-2016.
2019: covid -> reduction in production and advancement.
2020: supply chain disruption and chip shortage -> makes massive reduction

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Perkembangan Produksi = Pengurangan Produksi di tempat lain

Projections: increase in aluminum castings makes decline in cast iron production

western europe: cast iron decrease increase in aluminum alloy
shows production in lower complexity and lower value componenets is shifted to lower wage countries.
china: penurunan gray cast iron dari 57% 52.5% di antara 200-2015. peningkatan ductile iron dari 24% 32%.

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German Foundry Industry Association -> prognosis

Ferrous Foundries -> Recovery from covid believed to happen in Germany, Eastern Europe, and Turkey. While other major producing counties is having stagnation.
Asia:
- India growth
- china cannibalize japanese and korean production
NAFTA Region: mexico may profit, while asia (korea, taiwan) having general recovery.

Developments in automotive industry wake of electrification

china benefit disproportionately high

Similar Events such as the pandemic which causes economic consequences:

Breach of international law by Russian Federation's war of aggression against Ukraine
- Russia
  - a major producer of metals (aluminum)
  - oil and gas supplier higher cost for fossil fuels threatening europe casting industry (Germany)
- Ukraine titanium production

Changing Markets, Changing Products

Challanges and Trends

Major Challanges the industry faced back then (Bonollo et al, 2015)

Zero Defect Environment
Real time Process Control
Correlation between process parameters
Setup and optimization of techniques
Process-Quality interralations
Processess and tools to the foundry industry

Excluded

Competing production processes
Changing markets (automative industries rapid shift to E-mobility)
Environmental regulations (requiring foundries to become green)

Major Industry challanges (Büchner)

Globalization: emerging markets
Technology: lightweight design and process competence
Economics:
- Investment requirements
- Margin pressure
- Industrial consolidation
- Human Resources

Intinya: manufacturing industries (metal casting) is subject to change. The speed and impact of these changes has recently increased, fueled by industry 4.0 or smart factory

Current Development Directions

E-Mobility

Internal combustion engine Changed to electric power
Battery electric vehicles shows weight of cast components is 35-52% lower than ICE vehicles
To adapt, the casting industry is moving towards structural castings and developing components for electric powertrains, such as housings for motors and battery packs, reflecting a broader trend in response to the rise of e-mobility. Tesla's Gigacasting concept exemplifies this shift.

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Housing for electric powertrain components

Requires effective thermal management achieved by
- liquid cooling
- design approaches
  - includes high-pressure die casting (HPDC)
  - Cores are hard with HPDC Alternatives
    - Embedding hollow structures (aluminum tubes) enchance thermal conductivity & eliminates mismatch thermal expensien coefficient between fluid and casting
    - temporary fillers
    - internal structuring

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LDPC (Low pressure die casting) and Sand Casting allows for complex cores and varied designs, as demonstrated by companies like volkswagen

Rotor Casting

Need for high electrical conductivity require aluminum alloy
Complicated by
- Geometry of the casting Sufficient feeding is almost impossible Shrinkage, Porosity, Cold Runs.
- Porosity mechanical and electromagnetic effects.
- Mechanical: mass related unbalance
- Electromagnetic: inhomogenous current distribution (distortion in electromagnetic field, inhomogenity of electromagnetic forces)
- Reduce efficiency of the device.

Aluminum wants high conductivity, sufficient strength, heat treatment replace Al-Si with Al-Fe or Al-Ni eutectic system High Eutectic volume percentage achieved at low Fe or Ni low solubility in -Al phase guarantees high purity high conductive primary phases
Heat Treatment 520C Al-7Si fragmentation, spheroidization, and coarsening of the eutectic silicon can boost thermal conductivity

Automotive Structural Castings

E-mobility increase interest in structural casting.

Tesla Gigacasting technique streamlines manufacturing method produces front and rear vehicle bodies as single castings
Limited number of toolmakers complicates handling and transport new facilities are built adjacent to assembly plants.

Benefit from broader introduction of structural automotive castings

Improved thermal management of molds:
- reduction in cycle times by roughly 33%
- increase in die life up to 50%
Choice of alloys - no heat treatment required
- Elimination of process steps
- Elimination of distortion and residual stress
- Improvement in energy balance
Lightweight solution
- minimum thickness below 2.5mm
- advanced optimization tools

Additive Manufacturing

Additive manufacturing advantage

create complex geometries with extensive cores
parts produced by Laser Beam Melting exhibit superior mechanical properties
Wire Arc Additive Manufacturing has a slight environmental edge over green sand casting

Additive manufacturing hampered by

limited productivity (Laser beam melting produces slower than HPDC)
high material costs (metal powders as raw material exceed cast metal)

Environmental Issues

Green technology: aspects of its environmental impact include energy consumption, direct emmisions and waste.
Reduction in energy: advanced and higher efficiency production technologies
Ways to improve environmental balance:
- Use of inorganic binders in sand casting (reduce emmisions and waste)
- Reclamation and reuse of foundry sand (save natural resources and energy consumption)
- Microspraying in high pressure die casting (less waste and emmision, imrpove part quality)
- Heat treatment with natural gas can be
  - adapted to use hydrogen
  - replaced with electric systems